End module assembly for installation on a vehicle and method for making the same

ABSTRACT

The present invention relates to an end module assembly for installation on a motor vehicle and a method for assembling the same. The assembly comprises an exterior fascia configured to comprise a portion of a vehicle body when the assembly is installed on the vehicle. An external visible component is configured to be positioned in a predetermined orientation with respect to the fascia with surfaces thereof facing exteriorly of the fascia. The external component is positioned relative to the fascia such that the position controlling portion guides the external component into the predetermined orientation and supports the component thereat, thereby allowing the assembly to be installed on the vehicle without requiring reorientation of the component. The present invention also relates to a loading fixture for installing a front end module assembly onto a motor vehicle.

[0001] The present invention relates to an end module assembly forinstallation on either a front or rear end of a vehicle and a method formaking the same.

[0002] In the typical method of assembling a motor vehicle, the vehicleis moved down an assembly line and components are individually fastenedto the vehicle. In the front end of the vehicle, a radiator supportstructure is fastened to the vehicle body. Each of the componentsassociated with the vehicle front end are then fastened individually tothe support structure. In particular, external components, such as headlamps, fog lamps, and the grill, and the front end fascia are fastenedto the support structure individually. Fastening components in such amanner oftentimes causes the external components and the exterior fasciato be misaligned with respect to one another due to the potential errormargins associated with mounting each part individually. The sum ofthese error margins can cause component misalignment and poor vehicleaesthetics. To achieve proper component alignment, each externalcomponent must not only be aligned properly with respect to the fascia,but also with every other external component. Correcting these errorsconsumes time, increases labor costs, and decreases overallmanufacturing efficiency.

[0003] U.S. Pat. Nos. 5,123,695 and 5,358,304 disclose assemblies inwhich the front end fascia and the external visible componentsassociated with the front end are pre-assembled to each other andoptionally to an integrating structure or carrier panel. Thisarrangement allows the entire assembly to be mounted directly on thevehicle. The assembly disclosed in these patents, however, does notobviate the problems associated with the method described above becausethe fascia and the external visible components are still being mountedindividually and then the assembly is mounted to the vehicle. Due to theindividual mounting of the fixtures, the same component misalignmentproblems will occur.

[0004] It is therefore an object of the present invention to provide anend module assembly with superior component alignment between the fasciaand external components, thereby obviating the need for reorienting thecomponents after installation or accepting any misalignment becausethere are no adjustment provisions. In order to achieve the object ofthe present invention, there is provided an end module assembly forinstallation on a motor vehicle. The assembly comprises an exteriorfascia configured to comprise a portion of a vehicle body when theassembly is subsequently installed on the vehicle. An external visiblecomponent is configured to be positioned in a predetermined orientationwith respect to the fascia with surfaces of the component facingexteriorly of the fascia. The fascia has a position controlling portion.The external visible component is positioned relative to the fascia suchthat the portion guides the external component into the predeterminedorientation and supports the component thereat, thereby allowing theassembly to be installed on the motor vehicle without requiringreorientation of the component.

[0005] According to another aspect of the present invention, there isprovided a method for assembling an end module assembly for installationon a motor vehicle. The method comprises providing an exterior fasciaconfigured to comprise a portion of the vehicle body when the assemblyis subsequently installed on the motor vehicle. An external visiblecomponent is configured to be positioned in a predetermined orientationwith respect to the fascia with surfaces thereof facing exteriorly ofthe fascia. Both the external component and the fascia are positioned inan external assembling fixture. The assembling fixture provides fixedsurfaces positioned and configured to engage the exteriorly facingsurfaces of the external visible component and exteriorly facingsurfaces of the fascia so as to support the fascia in the predeterminedorientation with respect to the fascia. The external component and thefascia are thereafter secured in fixed relation while in the assemblingfixture so as to fix the component in the predetermined orientationthereof, thereby allowing the assembly to be installed on the vehiclewithout requiring reorientation of the external visible component.

[0006] According to yet another aspect of the present invention, thereis provided another method for assembling an end module assembly forinstallation on a motor vehicle. The method comprises providing anexterior fascia configured to comprise a portion of a vehicle body whenthe assembly is subsequently installed on the motor vehicle. An externalvisible component is configured to be positioned in a predeterminedorientation with respect to the fascia with surfaces of the externalvisible component facing exteriorly of the fascia. The component and thefascia are positioned relative to one another such that positioncontrolling portions of the fascia guide the component into thepredetermined orientation with respect to the fascia and support thefixture thereat, thereby allowing the module assembly to be subsequentlyinstalled on the motor vehicle without requiring reorientation of thecomponent.

[0007] An end module assembly constructed in accordance with theprinciples of the present invention provides superior componentalignment in comparison to assembling in which the component and thefascia are mounted individually to an integrating structure.Specifically, the present invention provides optimal part-to-part fitand accurately positions all end module components. The components mayinclude, but are not limited to, lamps, the grill, and decorative trim.It should be appreciated that the principles of the present inventionmay also be applied to rear end module assemblies as well as front endmodule assemblies.

[0008] Another aspect of the present invention relates to a loadingfixture for installing a front end module assembly onto a motor vehiclehaving a body and a frame movable relative to one another. The moduleassembly comprises an exterior fascia, external components, and bumperbeam supporting structure loosely supporting the bumper beam. Thefixture comprises a first lifting fixture constructed and arranged toengage the module assembly so as to lift and subsequently move themodule assembly into a module installation position wherein the moduleassembly can be installed on the vehicle with the fascia comprising aportion of the vehicle body. A second lifting fixture is constructed andarranged to engage and lift the bumper beam relative to the bumper beamsupporting structure such that, when the first lifting fixturesubsequently moves the module assembly into the installation positionthereof, the second lifting fixture supports the bumper beam in a bumperbeam installation position for subsequent attachment to the vehicleframe.

[0009] Other objects, features, and advantages will become apparent fromthe following detailed description, the accompanying drawings, and theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is an exploded view of a front end module assembly for aframed vehicle with integral radiator support structure in accordancewith a first embodiment of the present invention;

[0011]FIG. 2 is a perspective view of the embodiment shown in FIG. 1;

[0012]FIG. 3 is an exploded view of a front end module assembly for aframed vehicle without an integral radiator support structure inaccordance with a second embodiment of the present invention;

[0013]FIG. 4 is a perspective view of the embodiment shown in FIG. 3;

[0014]FIG. 5 is an exploded view of a front end module assembly for aunibody vehicle in accordance with a third embodiment of the presentinvention;

[0015]FIG. 6 is a perspective view of the embodiment shown in FIG. 5;

[0016]FIG. 7 is a perspective view of a front end module loadingfixture, disposed in operating relation with a front end module assemblyembodying the principles of the present invention; and

[0017]FIG. 8 is an enlarged sectional view taken along the line 8-8 inFIG. 7;

[0018]FIG. 9 is a cross-sectional view taken through a front end moduleassembly and an external assembly fixture wherein the assembly fixtureorients the external components and the fascia relative to one another;

[0019]FIG. 10 is a perspective view of a front end module assembly takenfrom the front;

[0020]FIG. 11 is a sectional view with the assembly positioned in anassembling fixture taken along lines 11-11 of FIG. 10 and through thefixture.

DETAILED DESCRIPTION OF THE DRAWINGS

[0021]FIGS. 1 and 2 show a front end module assembly, generallyindicated at 10, for a framed motor vehicle constructed in accordancewith the principles of the present invention. For simplicity ofexplanation, the module assembly 10 may be considered to comprise twogroups of parts: a forward group, or fascia sub-module, generallyillustrated at 12; and a rear group, or cooling sub-module, generallyillustrated at 16.

[0022] The forward group 12, includes a molded plastic fascia, generallydepicted at 18. Typically, the fascia 18 is relatively flexible withouta great deal of structural rigidity. The forward group 12 includes anumber of external visible components and other front end-associatedparts that are secured to the assembly 10 by conventional fasteners infixed relation with respect to the fascia 18. The external componentscomprise components which are to be positioned in a predeterminedorientation with respect to the fascia 18 with surfaces thereof facingexteriorly of the fascia 18. These external components include, but arenot limited to, an air dam 20, fog lamps 22, head lamps 24, and a grill26.

[0023] The air dam 20 is fixed to the bottom of the fascia 18, extendingapproximately the length of the fascia 18 in the cross-car direction. Apair of auxiliary or fog lamps 22 are mounted in fog lamp receivingopenings defined by holes 23 disposed in laterally spaced relation inthe front of the fascia 18. The head lamps 24 are laterally spaced andmounted in head lamp receiving openings defined by fascia panel recesses25 molded near the lateral or cross-car ends of the fascia 18 above theholes 23 for fog lamps 22. The fog lamps 22 form a snap-fit connectionwith holes 23. The recesses 25 have a plurality of holes 17 forreceiving various bolts and wiring components 27 that enable theheadlamps 24 to be loosely secured in proper centered position relativeto the recesses 25 in the fascia 18.

[0024] A pair of hood bumpers 30 are disposed near the opposite ends ofthe upper surface of an upper elongate horizontal portion 29 of thefascia 18. A hood latch assembly 28 is fixed to the forward surface ofthe upper horizontal portion 29 towards the center of the fascia 18.More particularly, latch assembly 28 has a downwardly depending flange31 which is fastened via bolts to the forward face of horizontal portion29. The latch assembly 28 further includes an upper flange portion 37extending rearwardly from flange portion 31 and disposed at right anglesto flange portion 31. The flange portion 37 is fixed by appropriatefasteners to an upwardly facing surface of horizontal portion 29. Thegrill 26 is fixed to the fascia 18 by appropriate fasteners at ahorizontally extending opening 21 disposed at the upper middle area ofthe front of the fascia 18.

[0025] A steel bumper beam 32 having a “C”-shaped cross section definingopening 47 is disposed across the width of the module assembly 10. Anelongated foam block 34 is hollowed out at its rear side and receives infixed relation the forward, lower, and upper portions of the bumper beam32 with the opening 47 of the C-section facing rearwardly. Therearwardly facing surfaces of the bumper beam 32 above and below theC-opening are provided with a plurality of fasteners in the form of nuts33 at the opposite end portions of the bumper beam 32. The nuts 33 arepreferably welded to the bumper beam. The rearward facing surface ofbumper beam 32 also has a pair of laterally spaced hook shaped beamcatches 45 which are used in mounting the bumper beam 32 on a vehicleframe as will be described. A pair of bumper beam supporting structuresin the form of fascia support brackets 36, 38 are secured to the back ofthe fascia 18. Base portions 41, 43 of the respective fascia supportbracket 36, 38 are secured in fixed relation with an inside base 19 ofthe fascia 18 by appropriate fasteners. Fasteners are also used to fixtabs 37 rising from each of a pair of upper legs 39 of fascia supportbrackets 36, 38 to the rear surface of a middle horizontal portion 15 ofthe fascia 18.

[0026] The brackets 36, 38 loosely capture the bumper beam 32 within legportions 39 so as to position the bumper beam 32 within the lower cavityformed above the inside base 19 of the fascia 18. A temperature sensor40 and a horn assembly 42 are secured to the base or bottom leg 41 ofone of the fascia support brackets 36, while an air bag sensor 44 issecured to the base 43 of the other fascia support bracket 38. Supportbrackets 36,38 each have a large aperture 35 which can receivetherethrough a plurality of bolts that can be used to secured the bumperbeam 32 (via nuts 33) to the vehicle frame front rail brackets 73 afterthe module assembly 10 is secured to the front end of the vehicle aswill be described.

[0027] The bumper beam 32 is not connected to or supported by any othercomponents within the module assembly 10, as it must eventually beconnected during final assembly with front rail brackets 73 of thevehicle frame. Conventional framed vehicle system dynamics allowrelative movement between the chassis system (such as the vehicle frame,bumper beam, etc.) and the body system (fascia, body panels, etc) duringvehicle operation. Thus, the bumper beam 32 merely rests between legs 39of the brackets 36 and 38 when the module is shipped for vehicleassembly. After assembly to the vehicle, the bumper beam 32 is fixed tofront rail brackets 73 in spaced relation to the fascia 18 to permitslight movement between fascia 18 and beam 32 during vehicle operation.The beam 32, when fixed to brackets 73 in the assembled vehicle ishidden by the fascia 18.

[0028] The rear group 16 includes a component integrating structure inthe form of a radiator support structure 48, generally extending thefull width of the module assembly 10. The rear group 16 furthercomprises a cooling module 50, including but not limited to a radiator,condenser, transmission oil cooler, and fan shroud 56. A plurality(preferably three) of upwardly extending tabs 51 are fixed to and extendupwardly from an upper portion of cooling module 50. The outer two tabs51 have forwardly extending portions provided with holes 381 which areused for lifting the module assembly 10 during installation on the frontend of a vehicle.

[0029] A plurality (preferably three) of downwardly extending tabs arefixed to and extend downwardly from a lower portion of cooling module50. A radiator center support “V” bracket 52 is fixed on the forwardface of the cooling module 50 at a central upper tab 51 and two of thelower outer tabs 53. The cooling module 50 has laterally outwardlyextending fascia mounting brackets 60 which are supported and mounted tothe uppermost surface of the upper legs 39 of the associated fasciasupport brackets 36 and 38.

[0030] The radiator support structure 48 has an opening 55 through whichthe cooling module 50 extends rearwardly. The radiator support structure48 further includes a lower wall 75 beneath opening 55 and to whichfasteners secure tabs 53 of the cooling module 50. A pair of tabs 59 areappended to the lower edge of the radiator support 48, and are disposedslightly inwardly to the lateral ends of the support 48. The tabs 59attach to radiator support frame mounts 67, which are fixed to thevehicle frame 63, through holes 61. Fender mounting brackets 54 eachhave elongated openings 57 disposed in an elongated leg portion 66 ofthe mounts 54. The elongated leg portions 66 are sandwiched between thetabs 59 of radiator support structure 48 and resilient isolator mountingstructures 67 of the vehicle frame 63. Fasteners pass through openings68 in the tabs 59, through the elongated openings 57 in the fendermounting brackets 54, and through holes 61 in the isolator mountingstructures 67. As a result, the radiator support structure 48 can befixed to the vehicle frame 63, with isolator mounts 67 providing forslight relative movement between the module 10 and frame 63. Each fendermounting bracket 54 further includes a truncated leg 70 disposed at aright angle to elongated leg 66. Truncated legs 70 facilitate securementof fenders 65 to the vehicle frame 63. Each fender 65 is provided with amounting tab 71 which has openings 72 that can be used to fasten thefenders 65 to opposite sides of the radiator support structure 48 atholes 64.

[0031] As shown, radiator support structure 48 also includes a pluralityof holes 90 that receive the bolts 27 of headlamps 24 to rigidly fix theheadlamps to the radiator support structure 48 and in proper centeredorientation to recesses 25. Radiator support structure 48 also has holes57 for receiving wiring from a wiring harness 80 that provides power toheadlamps 24. The wiring harness 80 also provides power to otherelectrical components of the front end module 10, such as fog lamps 22.Fixed to the front end of vehicle frame 63 are the previously describedpair of front frame brackets 73. During assembly, bumper beam 32 isconnected to front frame brackets 73 via appropriate bolts beingfastened through nuts 33 on the bumper beam 32.

[0032] It should be appreciated that the frame 63, fender 65, frontframe brackets 73 do not form part of module 10, but are particularlyconstructed and arranged to accommodate assembly of module 10 as a unitthereon.

[0033] To ensure proper orientation between the external components andthe fascia 18 prior to installation of the vehicle, it is important toproperly orient the components during the assembly with respect to onefixed reference point or template. Disclosed hereinbelow are two methodswhich will achieve such proper orientation.

[0034] In one method of the present invention, an external assemblingfixture, generally indicated at 500 in FIG. 9, functions as thetemplate. The assembling fixture 500 provides fixed surfaces includingfascia supporting surfaces 502, grill supporting surfaces 504, and headlamp supporting surfaces 506. These fixed surfaces 502, 504, 506 arepositioned and configured to engage exteriorly facing surfaces 508, 510of the external visible components (i.e., the head lamps 24 and grill26) and exteriorly facing surfaces 512 of the fascia 18 so as to supportthe external components in their predetermined orientations with respectto the fascia 18. Thus, the surfaces of the assembling fixture 500control the relative positioning between the fascia 18 and the externalcomponents, thereby eliminating the margins of error associated withpositioning each component individually.

[0035] The assembling fixture 500 is a large metal mold having anupwardly facing concave recess providing the aforesaid fixed surfaces.When the fascia 18 and external components are positioned in the mold,the fixed surfaces support the fascia 18 and components in place. It iscontemplated, however, that any fixture having surfaces capable ofsupporting the fascia 18 and external components in proper relativeorientation may be used as the assembling fixture 500.

[0036] While the fascia 18 and external components are positioned in themold, the assembly integrating structure (i.e., radiator supportstructure 48) is positioned rearwardly of the components and fascia 18.The components and fascia 18 are thereafter mounted to the radiatorsupport structure 48 so as to fix the external components in thepredetermined orientation with respect to the fascia, thereby allowingthe assembly to be installed on the vehicle without requiringreorientation of the components.

[0037]FIG. 9 also shows the step of inserting fasteners in the form ofbolts 514 through openings 516 formed in the support structure 48. Thesebolts 514 are threadingly engaged with openings 518 formed in the fascia18 and the components to fix the same in place. It is to be understood,however, that the same inserting and fastening step could be performedby bolts previously secured to the components and fascia 18 beingreceived in the same openings 518 as the support structure is beingmoved into position.

[0038] With the fascia 18 and external components fixed in place, theassembly 10 can then be removed from the assembling fixture 500 withoutany relative movement occurring between the components and the fascia18. The cooling module 50 can then be mounted to the radiator supportstructure 48 and all other internal components (e.g., wiring, etc.) canbe secured in place.

[0039] It is to be understood that FIG. 9 is simply a sectional view andother components will be positioned rearwardly of the fascia 18 beforemoving the support structure 48 into place. Specifically, it iscontemplated that the bumper beam 32 will be positioned rearwardly ofthe fascia 18 and the fascia support brackets 36, 38 will be secured tothe fascia 18 with the bumper beam 32 loosely captured as describedabove.

[0040] In another method of the present invention, the fascia 18 itselffunctions as the template. FIG. 11 schematically illustrates theassembling of the module assembly 10 according to this second method. Inthis method position controlling portions of the fascia 18 defined byposition controlling openings guide the external visible components intotheir proper orientations and support the components thereat, therebyallowing the assembly 10 to be installed on the motor vehicle withoutrequiring repositioning of the components. Specifically, the positioncontrolling opening 1020 formed on the fascia 18 receives positioncontrolling features 1022, 1024 on the external components so as toguide the components into proper orientation and support the componentsthereat. Preferably, the features 1022, 1024 are position controllingguide pins.

[0041] In the type of module assembly 10 of FIGS. 1 and 2, the radiatorsupport structure 48 would then be positioned rearwardly of the fascia18 and both the external components and the fascia 18 would then befastened to the support structure 48, thereby fixing the components inproper orientation. In the types of module assemblies described belowwith respect to FIGS. 3-6, the radiator support structure is pre-mountedto the vehicle itself and thus cannot serve as an anchor point for themodule assembly. In this type of module assembly—termed a‘non-structural’ module assembly—the external components may be secureddirectly to the fascia 18 in their proper orientations. To effect suchdirect securement, bolts may be used (as shown in FIGS. 3-6) or a snapfit connection may be formed between the position controlling features1022, 1024 and the position controlling openings 1020 to fix thecomponents in their proper orientation. Other securement means mayoptionally be used instead. In addition, the cooling module 50 will alsobe secured directly to the fascia 18, along with various othercomponents such as wiring and the fascia support brackets, rather thanto a radiator support structure 48.

[0042]FIGS. 3 and 4 show a front end module assembly 100 for a framedvehicle constructed in accordance with a second embodiment of theinvention. The embodiment shown in FIGS. 3 and 4 is similar in allrespects to the embodiment shown in FIGS. 1 and 2 except for thefollowing variations. Similar or corresponding parts are designated withthe same reference numerals in the figures.

[0043] The main difference in the module assembly 100 depicted in FIGS.3 and 4 is that its does not include an integral radiator supportstructure. Rather, the radiator support structure 148 in this embodimentforms part of the vehicle or “body-in-white” to which the module 100 ismounted. Thus, radiator support structure 148 does not form part of therear group 116, which only comprises cooling module 50.

[0044] In this embodiment, the radiator support structure 148 is mountedon the isolator mounts 67 on the front of the body in white framestructure 163 in the body shop as opposed to being bolted onto the frontbody as part of the module assembly, as in the previous embodiment.Thus, the step of mounting the fascia 18 and the external components isomitted in the method of assembly. In addition, the radiator supportstructure 148 has been slightly modified, such as being provided withtwo enlarged flanges 84 at its lower edge, thus replacing flange 59 andfender mounts 54 of the first embodiment. The flanges 84 are mounted ontop of and fixed to the isolator mounting structures 67.

[0045] Also in the embodiment of FIGS. 3 and 4, a pair of assembly aidstructures or spacers 46 cooperate with associated brackets 36 and 38.The assembly aid structures 46 are received within the brackets 36, 38to facilitate assembly of the bumper beam to the front end of a vehicleframe. More particularly, each of the assembly aids 46 are mountedbetween the upper and middle legs 39 of an associated one of thebrackets 36 or 38 and are received within the rearwardly facinglongitudinal opening 47 in the rearward end of bumper beam 32 so as tosupport the bumper beam 32 in vertically spaced relation between upperand middle legs 39 of the brackets 36 and 38 within the pre-assembledmodule 10. The spacers 46 position the bumper beam 32 in its properrelative orientation with respect to fascia 18, and other parts of themodule assembly 100, as will be achieved in the final assembly afterbumper beam 32 is fixed to front rail brackets 73. After assembly of thebumper beam 32 to brackets 73 at the front end of the body-in-white, theassembly aids 46 are removed and then discarded or reused. It should benoted, however, that the use of these aids 46 will be obviated by theloading fixture described hereinbelow.

[0046] The front end module assembly 200 of FIGS. 5 and 6 is similar tothe module illustrated in FIGS. 3 and 4 except that it is adapted for aunibody vehicle. In this embodiment, no assembly aids are provided, andthe bumper beam 32 is directly attached to the fascia support brackets36, 38 because there is no relative movement between bumper beam 32 andthe body (or any other relative movement between body/frame components)in a unibody design. Thus, isolator mounts are also omitted from thevehicle and the radiator support is rigidly welded to frame 263. Inaddition, the fascia support brackets 36, 38 are modified such that eachof the large central openings 35 are replaced by two small openings 286for receiving the bolts that are used to fix the nuts 33 of bumper beam32 to the brackets 36, 38 and also to the front rail brackets 73. Aswith the embodiment of FIGS. 3 and 4, the radiator support structure 248in FIGS. 5 and 6 are not part of the module assembly 200. The method ofmounting the radiator support structure 248 to the vehicle frame 263 isby welding it to the front end of the vehicle frame. In addition, ribmembers 290 are welded to the rear surface of radiator support structure248. The rib members 290 are in turn welded to the frame 263.

[0047] After the radiator support structure 248 is welded to the frame263, the front end module assembly 200 is secured to the frame 263 andradiator support structure 248. In particular, the tabs 53 of coolingmodule 50 are fastened to the lower panel 275 of radiator supportstructure 248, and the nuts 33 are secured to the front rail brackets 73mounted to the frame 263. Portions of the fascia 18 are also mounted toportions of the radiator support structure 248, and the latch flange 37is fastened to the upper surface of the upper portion 29 of the fascia18.

[0048] It is to be understood that any of the above embodiments may beused in conjunction with the subject matter in U.S. ProvisionalApplication of Longo et al., Serial No. 60/092,955, the entirety ofwhich is hereby incorporated into the present application by reference.

[0049] Referring now more particularly to FIGS. 7 and 8, a preferredfront end module loading fixture 300 is shown. The fixture 300facilitates handling of a front end module 10,100, or 200 in accordancewith the present invention. The front end module loading fixture 300 iscomprised of three assemblies: a main supporting frame, generallydepicted at 313, a first lifting fixture in the form of a pair of upperlifting fixtures, generally depicted at 315, and a second liftingfixture in the form of a pair of lower lifting fixtures, generallydepicted at 317. The main support frame 313 includes a pair of laterallyspaced, vertically extending parallel upright members 368. As shown inFIG. 8, the parallel members 368 have a lower portion 318 generallyextending straight upwards, a middle portion 320 which angles rearwardlyand upwardly from the lower portion 318, and an upper portion 322 whichextends straight upwards from the upper end of middle portion 320. Theuppermost portion 326 of each parallel member 368 extends upwardly andrearwardly and has a mounting ring structure 373 having a centralopening 374 of compatible size and configuration with the attachingmembers of a conventional hoisting device. The parallel upright members368 are secured and supported in parallel, vertical disposition by anX-shaped cross-member 370.

[0050] A rectangular lower frame structure 372 provides the base supportfor the fixture 300 and rests on an assembly support surface or floor.The bottom ends of the parallel members 368 are fixed or integrallyformed with the front corners of the lower frame structure 372.

[0051] The upper lifting fixtures 315 each basically comprise avertically elongated sleeve-like portion 376 and a lifting structure inthe form of a telescoping and rotating lift finger 378. The sleeve-likeportions 376 are disposed in surrounding relation to the upper portions322 of the respective upright members 368 and allow the upper liftingfixtures 315 to slide along and rotate around the parallel uprightmembers 368. Each rotating/telescoping lift finger 378 protrudeshorizontally and rearwardly from a sleeve portion 376 of an associatedupper lifting fixtures 315. Near the distal end of each lifting finger378 is a relatively short knob-like protrusion 380 which projectsupwards and is configured to be received within the openings 381 in thetabs 51 at the upper part of the front end module 10, 100, or 200. Adisk-like finger stop 382 is adjustably fixed at a desired verticalposition on upper portion 322 of each parallel member 368 below thesleeve portion 376 to serve as a lower stop for the sleeve 376 of theupper lifting fixture 315.

[0052] The lower lifting fixture 317 includes a lower lifting structurein the form of a vertical post or pick-up finger 384 fixedly secured toor integrally formed with the rearward corners of the lower framestructure 372 of the support frame 313. The pick-up fingers 384 are ofsuch height and diameter penetrate holes 383 in the lower surface of thebumper beam 32. An up/down stop disk 390 is integrally formed or fixedat an intermediate portion of each of the pick-up fingers 384 andprovides a lower support surface for the bumper beam 32 when the module10, 100, or 200 is lifted. Fixedly secured in surrounding relation tothe base of the pick-up finger 384, beneath stop disk 390, is a rubberstop/guide 386 which fits into a hole in the bottom surface of thefascia 18. This rubber guide 386 does not support any substantialvertical weight, but is used to prevent the lower portions of the frontend module 10 from tipping forward when the module 10 is lifted by thetelescoping/rotating lift fingers 378.

[0053] Use of the front end module loading fixture 300 in accordancewith principles of the invention entails positioning the loading fixture300 in front of the front end module 10, 100, or 200 such that thepick-up fingers 384 are somewhat lower than the bottom of the fascia 18,the fascia being supported from below by a shipping skid or crate. Theloading fixture 300 is moved toward the front end module 10, 100, or 200until the pick-up fingers 384 are beneath the lift finger holes 383 inbumper beam 32. The fixture 300 is then lifted as needed to insert thepick-up fingers 384 into lift finger holes 383. The height of liftfinger stop members 382 is adjusted such that the upper lifting fixtures315 along the parallel members 368 of the loading fixture aligns therotating/telescoping lifting fingers 378 so that they are approximatelyat the same height or slightly below the forwardly extending portions ofthe outer tabs 51 with openings 381. The telescoping lifting fingers 378are then extended and/or rotated so that upward projections 380 areimmediately below the openings 381. The fixture 300 is then hoisted sothat projections 380 are received within the openings 381 and so thatthe entire module is lifted via lifting fingers 378 and moved to aninstallation position with respect to the vehicle. The bumper beam 32 isindependently lifted by stops 390 below lift fingers 384.

[0054] The stops 390 lift the bumper beam 32 to a bumper installationposition a determined distance higher than the nominal design positionat which the beam is fixed to the frame brackets 73 in order to allowthe beam catch 45 to clear the top of the front frame brackets 73 uponrearward loading of the module. After the module 10, 100, 200 is securedto the vehicle (e.g., by fixing radiator support 48 to fenders 65 orbody in the first embodiment; or by fixing the fascia 18 and/or coolingmodule 50 to the fenders 65, radiator support 148, or other bodycomponents in the second embodiment), the fixture 300 is lowered to hookthe beam catch 45 on the frame brackets 73. The bumper beam 32 is now inthe design position and temporarily held until assembly bolts are usedat the next high level assembly line station to fix the bumper beam 32to the brackets 73 at nuts 33.

[0055] The loading fixture 300 thus allows the front end module 10, 100,or 200 to be lifted and supported to facilitate mounting thereof on theforward end of a vehicle frame assembly.

[0056] It will be thus seen that the object of the present invention hasbeen achieved by the foregoing embodiments. The embodiments describedherein, however, are provided to illustrate the functional andstructural principles of the present invention and are not intended tobe limiting. In contrast, the present invention is intended to encompassall modifications and alterations within the scope of the appendedclaims.

[0057] Any U.S. Patents or patent applications mentioned hereinabove andnot explicitly incorporated are now hereby incorporated into the presentapplication by reference.

[0058] It should be noted that the appended claims do not containlimitations or elements expressed in the ‘means for performing aspecified function’ format of 35 U.S.C. § 112, paragraph 6. This is toclearly point out that the applicant does not intend the claims to beinterpreted under 35 U.S.C. § 112, paragraph 6, so as to be limitedsolely to the structures disclosed in the present specification andtheir structural equivalents.

What is claimed:
 1. A method for assembling an end module assembly forinstallation on a motor vehicle, said method comprising the followingsteps: providing an exterior fascia configured to comprise a portion ofa vehicle body when said assembly is subsequently installed on the motorvehicle; providing an external visible component configured to bepositioned in a predetermined orientation with respect to said fasciawith surfaces of said external component facing exteriorly of saidfascia; positioning both said external component and said fascia in anexternal assembling fixture, said assembling fixture providing fixedsurfaces positioned and configured to engage said exteriorly facingsurfaces of said external component and exteriorly facing surfaces ofsaid fascia so as to support said external component in saidpredetermined orientation with respect to said fascia; thereaftersecuring said external component and said fascia in a fixed relation toone another while said external component and said fascia are positionedin said assembling fixture so as to fix said external component in saidpredetermined orientation with respect to said fascia, thereby allowingsaid assembly to be installed on the vehicle without requiringreorientation of said external component.
 2. The method of claim 1,further comprising the steps of positioning an assembly integratingstructure rearwardly of said external component and said fascia whilesaid component and said fascia are positioned in said assemblingstructure, wherein said securing step comprises mounting said fascia andsaid external component to said integrating structure so as to fix saidexternal component in said predetermined orientation.
 3. The method ofclaim 2, wherein said mounting step comprises inserting fastenersthrough openings formed through said integrating structure and fasteningsaid external component and said fascia to said integrating structurewith said fasteners.
 4. The method of claim 3, wherein said openingsformed through said integrating structure are oversized with respect tosaid fasteners to thereby accommodate manufacturing tolerances in saidfascia and said external component.
 5. The method of claim 4, whereinsaid assembling fixture is a mold having a concave recess for receivingsaid fascia and said external visible component, said recess providingsaid fixed surfaces.
 6. The method of claim 5, wherein said integratingstructure is a cooling module support structure and said method furthercomprises the step of mounting a cooling module to said cooling modulesupport structure.
 7. The method of claim 6, wherein said cooling modulecomprises a radiator, a condenser, a transmission oil cooler, and a fanshroud.
 8. The method of claim 6, wherein said external componentcomprises a pair of headlamps and said fascia includes a pair oflaterally spaced, forwardly facing openings positioned and configured toreceive said headlamps in predetermined orientations as aforesaid. 9.The method of claim 8, wherein said external component further comprisesa grill and said fascia includes a central, forwardly facing openingpositioned and configured to receive said grill in a predeterminedorientation as aforesaid.
 10. The method of claim 8, wherein saidexternal component further comprises a pair of auxiliary lamps and saidfascia includes a second pair of laterally spaced, forwardly facingopenings positioned and configured to receive said auxiliary lamps inpredetermined orientations as aforesaid.
 11. The method of claim 2,further comprising the steps of: positioning a bumper beam supportingstructure rearwardly of said fascia; mounting said bumper beamsupporting structure in fixed relation to said fascia; positioning abumper beam rearwardly of said fascia such that said bumper beamsupporting structure supports said bumper beam.
 12. The method of claim11, wherein relative movement is permitted between a frame and the bodyof the vehicle and said bumper beam supporting structure looselysupports said bumper beam such that, when said module assembly isinstalled on the vehicle, said bumper beam can be subsequently mountedto the vehicle frame and move along with the frame relative to thevehicle body.
 13. The method of claim 12, further comprising the stepof: positioning bumper beam assembly aids on said bumper beam supportingstructure, said bumper beam assembly aids being positioned andconfigured to support said bumper beam so that, when said moduleassembly is subsequently installed on the vehicle, said bumper beam canbe mounted to the vehicle frame without vertically repositioning thebumper beam and then the aids can be subsequently removed from thevehicle.
 14. The method of claim 12, wherein said bumper beam supportingstructures are fascia support brackets.
 15. The method of claim 11,wherein the vehicle is a unibody vehicle with no relative movementpermitted between a vehicle frame and the vehicle body and said steps ofpositioning said bumper beam and positioning said bumper beam supportingstructure comprises fixedly securing said bumper beam to said bumperbeam supporting structure so that, when said module assembly issubsequently installed on the vehicle, said bumper beam can be mountedto the vehicle frame without vertical repositioning.
 16. The method ofclaim 15, wherein said bumper beam supporting structures are fasciasupport brackets.
 17. A method for assembling an end module assembly forinstallation on a motor vehicle, said method comprising: providing anexterior fascia configured to comprise a portion of a vehicle body whensaid assembly is subsequently installed on the motor vehicle; providingan external visible component configured to be positioned in apredetermined orientation with respect to said fascia with surfaces ofsaid external component facing exteriorly of said fascia; positioningsaid external component and said fascia relative to one another suchthat a position controlling portion of said fascia guides said externalcomponent into said predetermined orientation with respect to saidfascia and supports said external component thereat, thereby allowingsaid assembly to be subsequently installed on the motor vehicle withoutrequiring reorientation of said external component.
 18. The method ofclaim 17, wherein said external component includes a positioncontrolling feature and said position controlling portion of said fasciaincludes a position controlling opening, said positioning stepcomprising inserting said position controlling feature into saidposition controlling opening such that structure defining said positioncontrolling opening guides said component into said predeterminedorientation with respect to said fascia and supports said externalcomponent thereat.
 19. The method of claim 18 further comprising thesteps of: positioning an assembly integrating structure rearwardly ofsaid fascia and said external component; and thereafter mounting saidexternal component and said fascia to said integrating structure whilesaid external component is in said predetermined orientation thereof soas to fix said external component thereat.
 20. The method of claim 19,wherein said mounting step comprises inserting fasteners throughopenings formed through said integrating structure and fastening saidexternal component and said fascia to said integrating structure withsaid fasteners.
 21. The method of claim 20, wherein said openings formedthrough said integrating structure are oversized with respect to saidfasteners to thereby accommodate manufacturing tolerances in said fasciaand said external component.
 22. The method of claim 21, wherein saidintegrating structure is a cooling module support structure and saidmethod further comprises the step of mounting a cooling module to saidcooling module support structure.
 23. The method of claim 22, whereinsaid cooling module comprises a radiator, a condenser, a transmissionoil cooler, and a fan shroud.
 24. The method of claim 23, wherein saidexternal component comprises a pair of headlamps and said fasciaincludes a pair of laterally spaced, forwardly facing openingspositioned and configured to receive said headlamps in predeterminedorientations as aforesaid.
 25. The method of claim 24, wherein saidexternal component further comprises a grill and said fascia includes acentral, forwardly facing opening positioned and configured to receivesaid grill in a predetermined orientation as aforesaid.
 26. The methodof claim 25, wherein said external component further comprises a pair ofauxiliary lamps and said fascia includes a second pair of laterallyspaced, forwardly facing openings positioned and configured to receivesaid auxiliary lamps in predetermined orientations as aforesaid.
 27. Themethod of claim 18, wherein said position controlling feature is aposition controlling guide pin configured to be received in saidposition controlling opening.
 28. The method of claim 27, wherein saidposition controlling guide pin is configured to form a snap-fitconnection with said position controlling opening when inserted thereinso as to fix said external component at said predetermined orientationthereof.
 29. The method of claim 18, further comprising the steps of:positioning a bumper beam supporting structure rearwardly of saidfascia; mounting said bumper beam supporting structure in fixed relationto said fascia; positioning a bumper beam rearwardly of said fascia suchthat said bumper beam supporting structure supports said bumper beam.30. The method of claim 29, wherein relative movement is permittedbetween a frame and the body of the vehicle and said bumper beamsupporting structure loosely supports said bumper beam such that, whensaid module assembly is installed on the vehicle, said bumper beam canbe subsequently mounted to the vehicle frame and move along with theframe relative to the vehicle body.
 31. The method of claim 30, furthercomprising the step of: positioning bumper beam assembling aids on saidbumper beam supporting structure, said bumper beam assembly aids beingpositioned and configured to support said bumper beam so that, when saidmodule assembly is subsequently installed on the vehicle, said bumperbeam can be mounted to the vehicle frame without the need for verticallyrepositioning the bumper beam and then the aids can be subsequentlyremoved from the vehicle.
 32. The method of claim 30, wherein saidbumper beam supporting structures are fascia support brackets.
 33. Themethod of claim 29, wherein the vehicle is a unibody vehicle with norelative movement between a vehicle frame and the vehicle body and saidsteps of positioning said bumper beam and positioning said bumper beamsupporting structure comprises fixedly securing said bumper beam to saidbumper beam supporting structure so that, when said module assembly issubsequently installed on the vehicle, said bumper beam can be mountedto the vehicle frame without vertical repositioning.
 34. The method ofclaim 33, wherein said bumper beam supporting structures are fasciasupport brackets.
 35. An end module assembly for installation on a motorvehicle, said assembly comprising: an exterior fascia configured tocomprise a portion of a vehicle body when said assembly is subsequentlyinstalled on the vehicle; an external visible component configured to bepositioned in a predetermined orientation with respect to said fasciawith surfaces of said external component facing exteriorly of saidfascia; said fascia having a position controlling portion; said externalcomponent being positioned relative to said fascia such that saidposition controlling portion guides said external component into saidpredetermined orientation and supports said component thereat, therebyallowing said assembly to be installed on the motor vehicle withoutrequiring reorientation of said component.
 36. An end module assemblyaccording to claim 35, wherein said module assembly is a front endmodule assembly.
 37. An end module assembly according to claim 36,wherein said position controlling portion is a position controllingopening and said external component has a position controlling feature,said external component being positioned relative to said fascia suchthat said position controlling feature is received within said positioncontrolling opening so that structure defining said position controllingopening guides said component into said predetermined orientation withrespect to said fascia and supports said external component thereat. 38.An end module assembly according to claim 37, further comprising anassembly integrating structure positioned rearwardly of both saidexternal component and said fascia, both said fascia and said externalcomponent being mounted to said integrating structure to thereby fixsaid external component in said predetermined orientation.
 39. An endmodule assembly according to claim 38, wherein said integratingstructure is a cooling module support structure, said assembly furthercomprising a cooling module mounted to said support structure.
 40. Anend module assembly according to claim 39, wherein said cooling modulecomprises a radiator, a condenser, a transmission oil cooler, and thefan shroud.
 41. An end module assembly according to claim 40, whereinsaid support structure has an opening through which said cooling moduleextends rearwardly, said support structure comprising a lower wallportion extending transversely with respect to said module assembly andbeneath said opening.
 42. An end module assembly according to claim 41,wherein said integrating structure has a plurality of fastener receivingopenings, said openings being positioned and configured to receivefasteners for mounting said fascia and said external component to saidintegrating structure.
 43. An end module assembly according to claim 42,wherein said fastener receiving openings are oversized with respect tosaid fasteners to allow for tolerances.
 44. An end module assemblyaccording to claim 38, wherein said external component comprises a pairof head lamps and said fascia has a pair of laterally spaced head lampreceiving openings configured to receive said head lamps.
 45. An endmodule assembly according to claim 44, wherein said external componentfurther comprises a grill and said fascia has a centrally positionedgrill receiving opening configured to receive the grill.
 46. An endmodule assembly according to claim 45, wherein said external componentfurther comprises a pair of auxiliary lamps and said fascia has a pairof auxiliary lamp receiving openings.
 47. An end module assemblyaccording to claim 38, further comprising: a bumper beam positionedrearwardly of said fascia; and bumper beam supporting structurepositioned and configured to support said bumper beam rearwardly of saidfascia.
 48. An end module assembly according to claim 47, whereinrelative movement is permitted between a frame and the body of thevehicle said bumper beam supporting structure loosely supporting saidbumper beam such that, when said module assembly is installed on thevehicle, said bumper beam can be subsequently mounted to the vehicleframe and move along with the frame relative to the vehicle bodystructure.
 49. An end module assembly according to claim 48, furthercomprising: bumper beam assembly aids associated with said bumper beamsupporting structure, said assembly aids being positioned and configuredto support said bumper beam such that, when said module assembly isinstalled on the vehicle, said bumper beam can be mounted to the vehicleframe without vertically repositioning the bumper beam and then the aidscan be subsequently removed from the vehicle.
 50. An end module assemblyaccording to claim 49, wherein said bumper beam supporting structuresare fascia support brackets.
 51. An end module assembly according toclaim 50, wherein said fascia support brackets have openings forreceiving front frame rail brackets of the vehicle frame to allow saidbumper beam structure to be mounted to said rail brackets.
 52. An endmodule assembly according to claim 37, wherein said position controllingfeatures are position controlling guide pins, said guide pins forming asnap-fit connection with said position controlling openings.
 53. An endmodule assembly according to claim 37, wherein a cooling module ismounted directly to said fascia.
 54. An end module assembly according toclaim 53, wherein said cooling module comprises a radiator, a condenser,a transmission oil cooler, and the fan shroud.
 55. An end moduleassembly according to claim 37, wherein said external componentcomprises a pair of head lamps and said fascia has a pair of laterallyspaced head lamp receiving openings configured to receive said headlamps.
 56. An end module assembly according to claim 55, wherein saidexternal component further comprises a grill and said fascia has acentrally positioned grill receiving opening configured to receive thegrill.
 57. An end module assembly according to claim 56, wherein saidexternal component further comprises a pair of auxiliary lamps and saidfascia has a pair of auxiliary lamp receiving openings.
 58. An endmodule assembly according to claim 37, further comprising: a bumper beampositioned rearwardly of said fascia; and bumper beam supportingstructure positioned and configured to support said bumper beamrearwardly of said fascia.
 59. An end module assembly according to claim58, wherein relative movement is permitted between a frame and the bodyof the vehicle said bumper beam supporting structure loosely supportingsaid bumper beam such that, when said module assembly is installed onthe vehicle, said bumper beam can be subsequently mounted to the vehicleframe and move along with the frame relative to the vehicle body.
 60. Anend module assembly according to claim 59, further comprising: bumperbeam assembly aids associated with said bumper beam supportingstructure, said assembly aids being positioned and configured to supportsaid bumper beam so that, when said module assembly is installed on thevehicle, said bumper beam can be mounted to the vehicle frame withoutthe need for vertically repositioning the bumper beam.
 61. An end moduleassembly according to claim 60, wherein said bumper beam supportingstructures are fascia support brackets.
 62. An end module assemblyaccording to claim 60, wherein said fascia support brackets haveopenings for receiving front frame rail brackets of the vehicle frame toallow said bumper beam structure to be mounted to said rail brackets.63. An end module assembly according to claim 58, wherein the motorvehicle is a unibody vehicle with no relative movement permitted betweenthe vehicle body and a vehicle frame, said bumper beam being fixedlysecured to said bumper beam supporting structure and being positioned tobe connected to the vehicle frame when the module assembly issubsequently installed on the vehicle.
 64. An end module assemblyaccording to claim 63, wherein said bumper beam supporting structuresare fascia support brackets.
 65. A loading fixture for installing afront end module assembly onto a motor vehicle having a body structureand a frame movable relative to one another, said module assemblycomprising an exterior fascia, external visible components, a bumperbeam, and bumper beam supporting structure loosely supporting the bumperbeam, said fixture comprising: a first lifting fixture constructed andarranged to engage the module assembly so as to lift and subsequentlymove the module assembly into a module installation position wherein theend module assembly can be installed on the vehicle with the fasciacomprising a portion of the vehicle body structure; and a second liftingfixture constructed and arranged to engage and lift the bumper beamrelative to the bumper beam supporting structure such that, when saidfirst lifting fixture moves the module assembly into the installationposition thereof, said second lifting fixture supports said bumper beamin a bumper beam installation position for subsequent attachment to thevehicle frame.
 66. A loading fixture according to claim 65, wherein thebumper beam has catching portions configured to be engaged with thevehicle frame, said second lifting fixture supporting the bumper beam insaid bumper beam installation position such that the catches will engagethe vehicle frame and support the bumper beam for subsequent attachmentwhen said loading fixture is disengaged from the front end moduleassembly.
 67. A loading fixture according to claim 66, furthercomprising: a main supporting frame; said first and second liftingfixtures being mounted to said supporting frame.
 68. A loading fixtureaccording to claim 67, wherein said supporting frame comprises a pair oflaterally spaced, vertically extending upright members, said firstlifting fixture comprising a pair of sleeve portions disposed insurrounding relation to upper portions of said upright members and alifting structure extending from each of said sleeve portions, saidlifting structure being constructed and arranged to engage and lift themodule assembly.
 69. A loading fixture according to claim 68, whereinsaid lifting structure is a lifting finger configured to be received inopenings on upper parts of the module assembly.
 70. A loading fixtureaccording to claim 69, further comprising a mounting ring provided oneach of said upright members, said mounting rings being configured to beattached to a hoisting device.
 71. A loading fixture according to claim70, wherein said main supporting frame comprises an X-shaped crossmember configured to support said upright members in vertical andparallel relation.
 72. A loading fixture according to claim 68, whereinsaid second lifting fixture comprises lower lifting structures connectedto lower portions of said upright members, said lifting structures beingpositioned and configured to engage and lift the bumper beam.
 73. Aloading fixture according to claim 72, wherein said lower liftingstructures comprise lifting fingers configured to be received withinopenings formed on the bumper beam and stops associated with saidlifting fingers, said stops being configured to engage and lift thebumper beam.